Thermally efficient window frame

ABSTRACT

A spacer frame for use in fabricating a window and a method of fabrication thereof is disclosed. The spacer frame for separating first and second glass lites from each other in window. The spacer frame includes a frame forming a multi-sided form comprising a first outwardly facing surface for supporting a first glass lite that is contiguous with a first intermediate wall portion and a second outwardly facing surface for supporting a second glass lite that is contiguous with a second intermediate wall portion. The first and second intermediate wall portions comprise a first material and are linked to each other and spaced from each other by a thermal interruption strip. The first and second intermediate wall portions and the thermal interruption strip comprise an intermediate wall that bridges the first and second outwardly facing surfaces. The spacer frame further includes a film overlaying the intermediate wall portion.

CROSS REFERENCES TO RELATED APPLICATIONS

The following application claims priority under 35 U.S.C. 119(e) toco-pending U.S. Provisional Patent Application Ser. No. 62/554,201 filedSep. 5, 2017 entitled THERMALLY EFFICIENT WINDOW FRAME. Theabove-identified provisional application is incorporated herein byreference in its entirety for all purposes.

FIELD OF THE INVENTION

The present disclosure relates to insulating glass units and moreparticularly to a thermally efficient window frame that comprises aspacer frame with a thermal barrier to reduce heat transfer across thespacer frame and through the insulating glass units.

BACKGROUND OF THE INVENTION

Insulating glass units (IGUs) are used in windows to reduce heat lossfrom building interiors during cold weather and to prevent the entranceof heat during warm weather. IGUs are typically formed by a spacerassembly sandwiched between glass lites. A spacer assembly usuallycomprises a frame structure extending peripherally about the unit, asealant material adhered both to the glass lites and the framestructure, and a desiccant for absorbing atmospheric moisture within theunit. The margins of the glass lites are flush with or extend slightlyoutwardly from the spacer assembly. The sealant extends continuouslyabout the frame structure periphery and its opposite sides so that thespace within the IGUs is hermetic.

One successful IGU construction has employed tubular, roll formedaluminum or steel frame elements connected at their ends to form asquare or rectangular spacer frame. The frame sides and corners werecovered with sealant (e.g., a hot melt material) for securing the frameto the glass lites. The sealant provided a barrier between atmosphericair and the IGU interior, which blocked entry of atmospheric watervapor. Particulate desiccant deposited inside the tubular frame elementscommunicated with air trapped in the IGU interior to remove theentrapped airborne water vapor, and thus, preclude its condensationwithin the unit. Thus, after the water vapor entrapped in the IGU wasremoved, internal condensation only occurred when the unit failed.

Alternatively, individual roll formed spacer frame tubes were cut tolength and “corner keys” were inserted between adjacent frame elementends to form the corners. In some constructions, the corner keys werefoldable so that the sealant could be extruded onto the frame sides asthe frame moved linearly past a sealant extrusion station. The frame wasthen folded to a rectangular configuration with the sealant in place onthe opposite sides. The formed spacer was then placed between glasslites and the IGU assembly completed.

A typical insulating glass unit (IGU) 10 is illustrated in FIG. 1. TheIGU 10 includes a spacer assembly 12 sandwiched between glass sheets, orlites, 14. The assembly 12 comprises a frame structure 16 and sealantmaterial for hermetically joining the spacer assembly 12 to the lites 14to form a closed space 20 within the IGU 10. The prior art IGU 10illustrated in FIG. 1 is in condition for final assembly into a windowor door frame.

The assembly 12 maintains the lites 14 spaced apart from each other toproduce the hermetic insulating “insulating air space” 20 between them.The typical frame 16 comprises a plurality of spacer frame segments, ormembers, 30 a-d connected to form a planar, polygonal frame shape,element juncture forming frame corner structures 32 a-d, and connectingstructure 34 for joining opposite frame element ends to complete theclosed frame shape. Traditionally a frame member 30 is has a channelshaped cross section defining a peripheral wall 40 and first and secondlateral walls 42, 44 (see FIGS. 2-3). The peripheral wall 40 extendscontinuously about the IGU 10 except where the connecting structure 34joins the frame member ends.

The frame 16 extends about the unit periphery, such that, in aninstalled window, a lite 14 exposed to the external temperature isthermally connected to a lite 14 that is exposed to an internaltemperature via the peripheral wall 40. This thermal connection causes athermal energy flow between the internal and external regions bound bythe window, causing the internal desired temperature to be altered bythe external not-desired temperature.

U.S. Pat. No. 5,361,476 to Leopold discloses a method and apparatus formaking IGUs wherein a thin flat strip of sheet material is continuouslyformed into a channel shaped spacer frame having corner structures andend structures, the spacer thus formed is cut off, sealant and desiccantare applied and the assemblage is bent to form a spacer assembly. U.S.Pat. No. 5,361,476 to Leopold is incorporated herein by reference in itsentirety for all purposes.

U.S. Pat. Pub. No. 2001/0032436 to Riegelman entitled “Insulated ChannelSeal for Glass Panes” and U.S. Pat. Pub. No. 2008/0060290 to McGlinchyconcerns a structure having a channel for a frame which separates windowpanes to form an insulated window and has a plurality of openingsthrough a wall of the channel that faces outward along the periphery ofthe frame and glass sandwich. In Riegelman, the openings are designed toprevent significant passage of sealant from the outside of the channelto the inside of the channel through the openings. This is done by thecross sectional area of each opening being so small that it resistsviscous flow of the sealant through the opening, or by a cover over theopening. U.S. Pat. Pub. No. 2001/0032436 to Riegelman is incorporatedherein incorporated by reference in its entirety for all purposes. U.S.Pat. Pub. No. 2008/0060290 to McGlinchy is herein incorporated byreference in its entirety and for all purposes.

Companies by the names of Edgetech and Nynex produce window spacerframes formed entirely of PVC having thermally efficient insulatingcharacteristics. U.S. Pat. Pub. No. 2008/0134596 to Brunnhofer et al.entitled “Spacer Profile for a Spacer Frame for an Insulating WindowUnit and Insulating Window Unit” concerns a mountable spacer profile forforming an intervening space. U.S. Pat. Pub. No. 2008/0134596 toBrunnhofer et al. is herein incorporated by reference in its entiretyand for all purposes.

SUMMARY

One aspect of the present disclosure includes a spacer for separatingfirst and second glass lites from each other in an insulating glass unit(IGU) for use in fabricating a window or door. The spacer framecomprising an elongated frame forming a multi-sided unit comprising afirst outwardly facing surface for supporting the first glass lite. Thefirst outwardly facing surface is contiguous with a first intermediatewall portion. The spacer frame further comprises a second outwardlyfacing surface for supporting the second glass lite. The secondoutwardly facing surface is contiguous with a second intermediate wallportion, wherein the first and second intermediate wall portionscomprise a first material and are linked to each other and spaced fromeach other by a thermal interruption strip. The first and secondintermediate wall portions and the thermal interruption strip comprisean intermediate wall that bridges the first and second outwardly facingsurfaces. Additionally, the spacer frame comprises a film for preventingfluid leakage, overlaying the intermediate wall portion.

Another aspect of the present disclosure comprises thermal stock for usein forming a spacer frame for use in an insulating glass unit (IGU). Thethermal stock comprising first and second frame stock portionscomprising a first thermal conductivity value, and a thermalinterruption strip coupling the first frame stock portion to the secondframe stock portion. The thermal interruption strip spacing the firstframe stock portion a gap distance from the second frame stock portion.The thermal interruption strip comprising a second thermal conductivityvalue, the second thermal conductivity being less than the first thermalconductivity value. Wherein an intermediate wall portion comprising thethermal interruption strip is covered by a film material for preventingfluid leakage.

Yet another aspect of the present disclosure comprises a method offorming thermal stock for use in insulating glass units. The methodcomprises forming a first and second frame stock portion, laterallylinking the first and second frame stock portions via a thermalinterruption strip. The thermal interruption strip spacing the firstframe stock portion from the second frame stock portion, and comprisinga lower thermal conductivity material than the material first and secondframe stock portions. The method further comprising overlaying thethermal interruption strip and at least a portion of the first andsecond frame stock portions with a film.

Yet another aspect of the present disclosure comprises an insulatingglass unit comprising first and second glass lites spaced apart fromeach other having inner facing surfaces that bound an interior region, amulti-sided channel shaped composite spacer frame for arranging saidfirst and second glass lites in a spaced apart, generally parallelrelation to each other. The spacer frame comprising an elongated thermalinterruption strip forming a middle portion of said composite spacerframe that extends around a periphery of the interior region bound bythe first and second glass lites, a first elongated metal side wallmember having a first outwardly facing side wall surface for orientingthe first glass lite and a first inwardly facing side wall surface thatbounds the interior region wherein the first elongated metal side wallmember includes a first embedded portion securing the first metal sidewall member to the thermal interruption strip, and a second elongatedmetal side wall member having a second outwardly facing side wallsurface for orienting the second glass lite and a second inwardly facingside wall surface that bounds the interior region wherein the secondelongated metal side wall member includes a second embedded portionsecuring the second metal side wall member to the thermal interruptionstrip. The spacer frame further comprising an adhesive materialinterposed between the outwardly facing side wall surfaces of said firstand second metal side wall members and the first and second glass litesfor arranging the first and second glass lites in spaced relation toeach other and a vapor barrier overlying at least a portion of thethermal interruption strip to impede contaminants from reaching theinterior region bounded by the first and second glass lites.

While another aspect of the present disclosure comprises thermal stockfor use in forming a spacer frame for use in an insulating glass unit(IGU), the thermal stock includes first and second metallic ribbons thatare substantially planar comprising first and second lateral ends, thefirst and second metallic ribbons having a first thermal conductivity; apolymeric thermal interruption strip formed over and between the secondlateral ends of the first and second metallic ribbons, the polymericthermal interruption strip spacing the first and second metallic ribbonsby forming a gap between the second lateral ends, the gap being fixedlywithin the polymeric thermal interruption strip, the polymeric thermalinterruption strip comprising a second thermal conductivity, the secondthermal conductivity is less than the first thermal conductivity; thepolymeric thermal interruption strip further comprising spaced first andsecond mirrored converging lateral ends forming a sandwich connectionwith and over the second lateral ends of the first and second metallicribbons, the sandwich connection extending toward the first lateral endsto cover a portion of the first and second metallic ribbons beyond thesecond lateral connection ends, the polymeric thermal interruption stripfurther comprising a planar body that connects the first and secondspaced mirrored converging lateral ends, the planar body covers aportion of the metallic ribbons and the entire gap between the secondlateral ends of the first and second metallic ribbons; and a filmmaterial covering a portion of first and second longitudinal sides ofthe first and second metallic ribbons and an entire first and secondlongitudinal sides of the polymeric thermal interruption strip.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages of the presentdisclosure will become apparent to one skilled in the art to which thepresent invention relates upon consideration of the followingdescription of the invention with reference to the accompanyingdrawings, wherein like reference numerals refer to like parts unlessdescribed otherwise throughout the drawings and in which:

FIG. 1 is perspective view of a typical insulating glass unit as knownin the prior art;

FIG. 2 is a top view of a typical spacer frame that forms part of thetypical insulating glass unit of FIG. 1 as known in the prior art;

FIG. 3 is a left side elevation view of FIG. 2 as known in the priorart;

FIG. 4 is perspective view of an insulating glass unit (IGI) constructedin accordance with one example embodiment of the present disclosure;

FIG. 5 is a plan view of flat thermal stock after a punching operationthat will be formed into one or more thermal spacer frame assembliesbefore the flat stock is roll formed or has sealant applied;

FIG. 5A is a top view of the thermal spacer frame assembly located inthe IGU illustrated in FIG. 4 after a roll forming operation isperformed on the flat thermal stock illustrated in FIG. 5;

FIG. 6A is a left side elevation view of FIG. 5A;

FIG. 6B is cross sectional view of the spacer frame assembly of FIG. 6Ataken along lines 6B-6B;

FIG. 6C is a fragmentary elevation view of a thermal space frame formedfrom the spacer assembly of FIG. 6A, which is illustrated in a partiallyconstructed condition;

FIG. 7 is an elevation depiction of a production assembly for use inproducing the thermal spacer frame assemblies of the present disclosurethat are used in an IGU;

FIG. 8 is a front elevation view of thermal sheet stock constructed inaccordance with one example embodiment of the present disclosure, thethermal sheet stock used to form a thermal spacer frame assembly;

FIG. 9 is a top perspective view of a thermal spacer frame assemblycomprising roll formed thermal sheet stock in accordance with oneexample embodiment of the present disclosure;

FIG. 10 is a top perspective view of thermal sheet stock;

FIG. 11 is a front elevation view of thermal sheet stock being rollformed;

FIG. 12 is a magnified view of FIG. 11;

FIG. 13 is a cross-section taken along line 13-13 of FIG. 4;

FIG. 14 is a top plan view of first and second sheet stock portions;

FIG. 14A is a perspective view of a thermal spacer frame assembly inaccordance with one example embodiment of the present disclosure;

FIG. 15A is cross-section view of an isotherm of the traditional IGU ofFIG. 1 taken along lines 15A-15A; and

FIG. 15B is cross-section view of an isotherm of the IGU of FIG. 4 takenalong lines 13-13.

Skilled artisans will appreciate that elements in the figures areillustrated for simplicity and clarity and have not necessarily beendrawn to scale. For example, the dimensions of some of the elements inthe figures may be exaggerated relative to other elements to help toimprove understanding of embodiments of the present disclosure.

The apparatus and method components have been represented whereappropriate by conventional symbols in the drawings, showing only thosespecific details that are pertinent to understanding the embodiments ofthe present disclosure so as not to obscure the disclosure with detailsthat will be readily apparent to those of ordinary skill in the arthaving the benefit of the description herein.

DETAILED DESCRIPTION

Referring now to the figures generally wherein like numbered featuresshown therein refer to like elements throughout unless otherwise noted.The present disclosure relates to insulating glass units and moreparticularly to a thermally efficient window frame that comprises aspacer frame with a thermal barrier to reduce heat transfer across thespacer frame and through the insulating glass units.

A double pane insulating glass unit (IGU) 333 is illustrated in FIG. 4.The IGU 333 includes a spacer assembly 312 sandwiched between glasssheets, or lites 314. The assembly 312 comprises a frame 316 and sealantmaterial (omitted for clarity) for hermetically joining the spacerassembly 312 to the lites 314 to form a closed space 320 within the IGU333. The IGU 333 is illustrated in FIG. 4 as in condition for finalassembly into a window or door frame, not illustrated, for ultimateinstallation in a building. The IGU 333 as illustrated in FIG. 4includes muntin bars “m” that provide the appearance of individualwindow panes. It would be appreciated by one having ordinary skill inthe art that multi-pane IGUs were contemplated, and the frame structuresused therein would be substantially the same as the frame 316 describedwith regard to the IGU 333. Further discussion of multi-pane IGUs andtheir assembly process is found in U.S. Pat. Nos. 9,416,583 and9,534,439, which are assigned to the assignee of the present disclosure.Both U.S. Pat. Nos. 9,416,583 and 9,534,439 are incorporated herein intheir entireties for all purposes.

The assembly 312 maintains the lites 314 spaced apart from each other toproduce the hermetic insulating “insulating air space” 320 between them.The frame 316 and the sealant body 318 (see FIG. 13) co-act to provide astructure which maintains the lites 314 properly assembled with thespace 320 sealed from atmospheric moisture over long time periods duringwhich, the IGU 333 is subjected to frequent significant thermalstresses. A desiccant 319 (see FIG. 13) removes water vapor from air, orother volatiles, entrapped in the space 320 during construction of theIGU 333.

The sealant 318 both structurally adheres the lites 314 to the spacerassembly 312 and hermetically closes the space 320 against infiltrationof airborne water vapor from the atmosphere surrounding the IGU 333. Onesuitable sealant is formed from a “hot melt” material, which is attachedto the frame 316 sides and outer periphery to form a U-shaped crosssection.

The frame 316 extends about the unit periphery to provide a structurallystrong, stable spacer 312 for maintaining the lites 314 aligned andspaced while minimizing heat conduction between the lites via the frame.The preferred frame 316 comprises a plurality of spacer frame segments,or members, 330 a-d connected to form a planar, polygonal frame shape,element juncture forming frame corner structures 332 a-d, and connectingstructure 334 (see FIG. 6C) for joining opposite frame element ends 362,364 to complete the closed frame shape.

The frame member 330 is elongated and has a channel-shaped crosssection, defining a peripheral wall 340 and first and second lateralwalls 342, 344 (see FIGS. 5A, 9, and 13). The peripheral wall 340comprises frame stock 306, 308 spaced from each other and linked to eachother by a thermal interruption strip 302 (see FIGS. 5A, 9, and 13, and14). A film 304 overlays at least a portion of the stock 306, 308, andthe thermal interruption strip 302 (see, for example, FIG. 9). Theperipheral wall 340 extends continuously about the IGU 333 except wherethe connecting structure 334 joins the frame member ends 362, 364. Thelateral walls 342, 344 are integral with respective opposite peripheralwall edges. The lateral walls 342, 344 extend inwardly from theperipheral wall 340 in a direction parallel to the planes of the lites314 and the frame 316. The illustrated frame 316 has stiffening flanges346 formed along the inwardly projecting lateral wall edges. The lateralwalls 342, 344 add rigidity to the frame member 330 so it resistsflexure and bending in a direction transverse to its longitudinalextent. The flanges 346 stiffen the walls 342, 344 so they resistbending and flexure transverse to their longitudinal extents.

Illustrated in FIG. 5 is the continuous metal ribbon or flat stock 348that is roll formed into the channel shaped cross section defining theperipheral wall 340 and first and second lateral walls 342, 344 (seeFIGS. 5A, 9, and 13). The flat stock 348 is passed through a stampingstation and punched by a number of dies to form notches 350 andweakening zones 352 for corner folds 332, a connecting structure 334, anose 362, gas fill apertures 371, 372, and end cut 380. The thermalinterruption strip 302 is illustrated in dashed lines for clarity as thefilm 304 overlays said thermal interruption strip. A punch strip 336 offlat thermal stock 310 forms a thermal spacer frame assembly 312 asillustrated in repeating sections by dimension “L” from the continuousstrip 348. The punch strip 336 is eventually sheared to make a spacerframe assembly 312 at end 380 and the nose 362, leaving scrap piece 382.Alternatively, the punching or shearing operation is a single hitoperation in which the width of the shear equals that of scrap piece382, leaving no scrap or need for a double hit operation. Furtherdiscussion relating to the shearing or punching operation is discussedin U.S. Pat. No. 8,720,026, which is incorporated herein by reference inits entirety. The gas fill apertures 371, 372 comprise holes punchedinto the flat thermal stock 310.

The frame 316 is initially formed as a continuous straight channelconstructed from thermal stock 310, wherein the thermal stock comprisestwo independent thin ribbons of stock material 306, 308 (e.g., 304stainless steel having a thickness of 0.006-0.010 inches) linked via thethermal interruption strip 302, and at least partially overlaid with thefilm 304. It should be appreciated that the metal stock 306 could alsobe 1020 steel, mild steel, hardened steel, aluminum, CrMo steel, nickel,carbon steel, and the like.

In one example embodiment, the frame stock 306, 308 comprises othermaterials, such as galvanized and/or tin plated steel, aluminum and/orplastic. The thermal interruption strip 302 in one example embodimentcomprises a non-thermally conductive material such as a polymer (e.g.,aliphatic or semi-aromatic polyamides (Nylon), polyethylene, polyester,epoxy, etc.), a plastic (e.g., polyethylene terephthalate, high-densitypolyethylene, polyvinyl chloride, etc.) rubber, hardening agents (e.g.,calcuim carboniate, talc, barium sulphate, glass fibers, etc.), bondingagents (e.g., polyvinyl acetate) or a combination thereof. The thermalinterruption strip 302 comprises a durometer between 70-90 Shore D whichhas a sufficient rigidity at temperatures up to below 100° C., tomaintain the shape of the channel, and the walls 342, 344, yet providethe flexibility to bend when assembled (see FIG. 6C) at the cornersC1-C4 without separation at corners C1-C4. The film 304 comprises an airfight film such as a metalized polyester film, to prevent loss ofthermally efficient insulating fluids (e.g., He, Ne, Ar, Kr, Xe, or thelike) from the space 320, the flexibility of the film 304 also providesstrength to the spacer frame and thermal interruption strip 302 toprevent fracturing during the bending at the corners C1-C4. In oneexample embodiment, the film 304 comprises a low moisture vaportransition rate (MVTR) barrier film. Examples of products that can beused as film 304 include Mylar resin (e.g., Polyethylene Terephthalate(PET)), 3M's P Model #850 Polyester film, and the like.

As described more fully below, the corner structures 332 are made tofacilitate bending the frame channel to the final, polygonal frameconfiguration in the IGU 333 while assuring an effective vapor seal atthe frame corners and properly aligning apertures 371, 372. The gas fillapertures 371, 372 comprise holes punched into the thermal interruptionstrip 302. The gas fill apertures 371, 372 are used to either inject thespace 320 in the IGU 333 with a liquid and/or solid, or to evacuate thespace. In one example embodiment, the corner structures 332 are manuallyor automatically bent when the frame 316 is maintained at an elevatedbending temperature. The bending temperature is determined based upon amelting temperature and/or a heat distortion temperature of the thermalinterruption strip 302. In this embodiment, the apertures 371, 372 areformed while the thermal interruption strip 302 is at the bendingtemperature, to facilitate aperture formation. In another embodiment,the apertures 371, 372 are formed through the thermal interruption strip302 utilizing a punch and/or screw before or after roll forming.

In yet another embodiment, the apertures 371, 372 are formed through thethermal interruption strip 302 via a hot or thermal punch, cold punch,and/or a hole drilling mechanism. Sealant 318 is applied and adhered tothe channel before the corners 332 are bent. As shown in the illustratedembodiment of FIGS. 5, 5A, and 6A, the corner structures 332 initiallycomprise notches 350 and weakened zones 352 formed in the walls 342, 344at frame corner locations. The notches 350 extend into the walls 342,344 from the respective lateral wall edges. The lateral walls 342, 344extend continuously along the frame 316 from one end to the other. Thewalls 342, 344 are weakened at the corner locations 332 because thenotches reduce the amount of lateral wall material, a portion of thefilm 304, and eliminate the stiffening flanges 346 and because the wallsare punched and stamped to weaken them at the corners. At the same timethe notches 350 are formed, the weakened zones 352 are formed. Theseweakened zones are cut into the strip 310, but not all the way through.When this strip 310 is rollformed, the weakened zones 352 can springback and have an outward tendency.

The connecting structure 334 secures the opposite frame ends 362, 364together when the frame 316 has been bent to its final configuration.The illustrated example embodiment of FIG. 6C, the connecting structure334 comprises a connecting tongue structure 366 continuous with andprojecting from the frame structure end 362 and a tongue receivingstructure 370 at the other frame end 364. The illustrated exampleembodiment tongue and tongue receiving structures 366, 370 areconstructed and sized relative to each other to form a telescopic joint358. When assembled, the telescopic joint 358 maintains the frame in itsfinal polygonal configuration prior to assembly of the unit 333.

In a second embodiment, such as in the illustrated example embodimentsof FIGS. 5A, 6A, 6B, and 6C, the connecting structure 334 comprises astop 364 that is formed by stamping dies at a stamping station 104 asdescribed below. The connecting structure 334 is inserted into anopposite frame end 354 or the leg member 330 d when the thermal spacerframe assembly 312 has been bent to its final configuration. That is,rotating the thermal spacer frame assembly 312 members 330 (from thelinear configuration of FIGS. 5A and 6A) in the direction of arrows A,B, C, and D as illustrated in FIG. 6C and particularly, inserting theframe structure end or nose 362 of the connecting structure 334 into anopposite channel 355 formed at the opposite end 354 of segment 330 dwith concomitant rotation of the segments (arrows A-D). This concomitantrotation continues until the connecting structure 334 slides into theopposite channel 355 of segment 330 d at the opposite end 354. In theillustrated example embodiment of FIG. 6C, the opposite end 354 engagespositive stops 364 in the connecting structure 334 forming a telescopicunion 358 and lateral connection 360 that is spaced from the corners332. It would be appreciated by one having ordinary skill in the artthat the lateral connection 360 and/or the telescopic union 358 could belocated anywhere between the first and fourth corners 332 a, 332 d.Further discussion as to the stop 364 and lateral connection 360 that isspaced from the corners 332 is discussed in U.S. Pat. No. 9,428,953, U.SPatent Publication No. 2015/0361713, which are incorporated herein byreference in its entirety and for all purposes.

The Production Line 100

An operation by which elongated window components are made isschematically illustrated in FIG. 7 as a production line 100 throughwhich thermal sheet stock 310 comprising the two thin, relatively narrowribbons of sheet metal stock 306, 308 linked by the thermal interruptionstrip 302 and the film 304 is fed endwise from a coil into one end ofthe assembly line and substantially completed elongated windowcomponents 312 emerge from the other end of the line 100.

The line 100 comprises a stock supply station 102, a first formingstation 104, a transfer mechanism 105, a second forming station 110, aconveyor 113, a scrap removal apparatus 111, third and fourth formingstations 114, 116, respectively. Wherein within the line 100, partiallyformed spacer members are separated from the leading end of the thermalsheet stock 310, the thermal sheet stock is roll formed, and framecorner locations are deformed. At a desiccant application station 119desiccant is applied to an interior region of the spacer frame member,and at an extrusion station 120 sealant is applied to the yet to befolded frame member. A scheduler/motion controller unit 122 interactswith the stations and loop feed sensors to govern the spacer stock size,spacer assembly size, the stock feeding speeds in the line, and otherparameters involved in production. A preferred controller unit 122 iscommercially available from Delta Tau, 21314 Lassen St, Chatsworth,Calif. 91311 as part number UMAC. In one embodiment a separatecontroller 122′ controls the desiccant application and adhesive orsealant application. Additional details of a representative spacer framefabrication system are contained in US Pat. Pub. No. 2006/0075719 toJames et al., which is incorporated herein by reference.

Thermal Stock 310

In one example embodiment, the spacer assembly 312 enhances the thermalproperties of the resulting window by interrupting thermal energy flowof energy through an installed window. The thermal energy flow betweenan interior wall and an exterior wall is interrupted by the presence ofthe thermal interruption strip 302. For example, the thermalinterruption strip 302 better maintains the temperature of the window'sinwardly facing edge in winter by impeding heat flow from inside a homeor other building and impeding the energy loss caused by lowertemperature from the outwardly facing edge of the window.

In the illustrated example embodiment of FIG. 13, heat flow disruptionis accomplished by the thermal conductivity interruption created by thethermal interruption strip 302 of the peripheral wall 340 of the frame312. The thermal interruption strip 302 links an inner edge 303 b of thefirst metal strip 306 and an inner edge 307 b of the second metal strip308 (see FIG. 14). The links of the inner edges 303 b and 307 b in theillustrated example embodiment is in an alternating sinusoidal mannerincreasing the strength and support between the thermal interruptionstrip 302 and the ribbons 306.

The thermal interruption strip 302 comprises a polymer bridge 399. Thepolymer bridge 399 comprises a mechanically crimped polymer bridge withthe frame member before or after roll forming, a co-extruded polymerbridge, a molded polymer bridge, or the like. In this embodiment, thethermal stock 310 is formed by an automated apparatus. In one exampleembodiment, such as illustrated in FIG. 8, when the thermal interruptionstrip 302 comprises the mechanically crimped polymer bridge, the thermalinterruption strip 302 comprises a central portion 302 a, an upperportion 302 b, and a lower portion 302 c, wherein the lower portion ispositioned to interact with bottom faces 306 b, 308 b of the frame stock306, 308, the central portion is positioned between the frame stock andon top of the lower portion, and the upper portion 302 a is positionedon to interact with top faces 306 a, 306 b of the frame stock and thecentral portion. The upper, central, and lower portions 302 a-302 c aremechanically crimped together, manually or automatically, to form thethermal interruption strip 302 and to bond the thermal interruptionstrip to the frame stock 306, 308, to form the thermal stock 310.

In another example embodiment, when the thermal interruption strip 302comprises the co-extruded polymer bridge, the thermal interruption strip302 is formed as a single unit while interacting with the frame stock306, 308. The frame stock 306, 308 is aligned relative to an extrusionapparatus, and the polymer bridge material is extruded, manually orautomatically, onto the frame stock to form the thermal interruptionstrip 302 linking the frame stock and the thermal interruption strip302.

In the illustrated example embodiment of FIGS. 8, 9, and 10, the thermalinterruption strip 302 is a polygon, and in particular, a hexagonalpolygon that provides strength and support between the thermalinterruption strip and ribbons 306, 308. This construction assists inproviding support for high stress conditions that occurs on the strip,ribbon, and connection therebetween, especially at the corners when thespacer frame is bent for assembly. In the illustrated exampleembodiment, the hexagonal construction forms a hexagonal prismcross-section as seen in FIG. 10. The hexagonal prism cross-sectionextends longitudinally around the entire profile of the spacer frame.Laterally, the hexagonal prism cross-section includes mirrored first andsecond ends having upper and lower transverse ends extending to a pointforming a sandwich connection with the ribbons 306, 308 starting at thefirst and second stability extents and extending to and beyond ends 303b and 307 b (see FIGS. 8 and 10). The hexagonal prism cross-sectionfurther comprises a planar body that connects the spaced mirrored firstand second ends and covers the stability extents and gap between theends 303 b and 307 b as illustrated in FIGS. 8 and 10).

In yet another example embodiment, when the thermal interruption strip302 comprises the molded polymer bridge, the thermal interruption strip302 is formed by positioning the frame stock 306, 308 relative to athermal interruption strip mold, and filling the mold with the thermalinterruption strip material. The frame stock 306, 308 is alignedrelative to the mold to obtain desired dimensions of the thermalinterruption strip 302 relative to the frame stock. The polymer bridgematerial is injected, manually or automatically, onto the mold to formthe thermal interruption strip 302 and, thus, the thermal stock 310. Inyet another example embodiment, the frame stock 306, 308 is positionedafter the mold has been filled, but while the thermal interruption stripmaterial is still pliable (e.g., while a temperature of the thermalinterruption strip material is over a temperature at which the materialwould become inflexible).

In the illustrated example embodiment of FIG. 8, the thermalinterruption strip 302 extends a first stability distance 313 over a topface 306 a and/or a bottom face 306 b of the first frame stock portion306 and a second stability distance 315 over a top face 308 a and/or abottom face 308 b of the second frame stock portion 308 to increase astrength of the linking of the first and second frame stock portion. Thethermal interruption strip 302 provides a gap distance 311 between theinner edges 303 b, 307 b (see FIGS. 8 and 14) of the first and secondframe stock portions 306, 308. The first and second stability distances313, 315, and the gap distance 311 are proportional to a final width 317of the spacer frame 316 and/or a stock width 327 of the stock 310 (seeFIGS. 8-9). For example, a sum of the first and second stabilitydistances 313, 315, and the gap distance 311 is between ⅛th to about ¼thof the total stock width 327. The first and second stability distances313, 315 are proportional to the gap distance 311 (e.g., at a ratio ofbetween 1:2 to 1:4). In one example embodiment, the greater the gapdistance 311 the greater the first and second stability distances 313,315. In another example embodiment, the first and second stabilitydistances 313, 315 are substantially equal to the gap distance 311. Inyet another example embodiment, the sum of the first and secondstability distances 313, 315, and the gap distance 311 is less thanfinal width 317 of the spacer frame 316.

In another embodiment, the thermal interruption strip 302 is glued oradhered (e.g., with a pressure sensitive adhesive) to the frame stock306, 308 (see FIGS. 8, and 14). In this embodiment, the thermal stock310 is formed by an automated strip laminating apparatus. When thethermal interruption strip 302 is linked to the frame stock 306, 308 viaadhesives or glue, the lower portion 302 c is positioned to interactwith bottom faces 306 b, 308 b of the metal strips 306, 308, the centralportion 302 a is positioned between the frame stock portions and on topof the lower portion, and the upper portion 302 b is positioned on topfaces 306 a, 306 b) of the frame stock and the central portion, whereinan adhesive or glue is disposed between the upper, central, and lowerportions, and/or the frame stock. The upper, central, and lower portions302 a-302 c are glued/adhered together, manually or automatically,(e.g., using pressure, such as a uniform pressure of 20-30 psi) to formthe thermal interruption strip 302 and additionally, glued/adhered tothe frame stock 306, 308, to form the thermal strip 310.

In yet another example embodiment, the frame stock 306, 308 (see FIG.14) comprise serrations or shapes that add surface area to aid adherenceof the thermal interruption strip 302 to along the inner edges 303 b,307 b of the frame stock 306, 308. In the illustrated example embodimentof FIG. 14, the first frame stock portion 306 comprises intruding 306 aand protruding 306 b undulations. The second frame stock portion 308comprises intruding 308 a and protruding 308 b undulations that arecomplementary intruding 306 a and protruding 306 b undulations of thefirst frame stock portion 306. In an additional example embodiments, theframe stock portion 306, 308 comprise interruptions (e.g., holes 341,mesh material 339, etc.) (see FIG. 14) along and adjacent to the inneredges 303 b, 307 b of the metal strips 306, 308 to provide added gripstrength/bonding surface area to the thermal interruption strip 302. Thegap distance 311 between the inner edges 303 b, 307 b is variable and isa factor in minimum spacer width capability. For example, a larger gapdistance 311 is more thermally efficient. In one example embodiment, thethermal interruption strip 302 provides the gap distance 311 having arange between about ⅛″ (inches) to about ¼″ (inches). In another exampleembodiment, the thermal interruption strip 302 comprises a thermalinterruption strip thickness 323 (see FIG. 13). The thermal interruptionstrip thickness 323 having a range between about ⅛″ (inches) to about¼″(inches). The thermal interruption strip 302 disrupts heat transferacross the wall from one side wall 342 to the opposed side wall 344while maintaining a structural integrity of the wall 340.

The film 304 is applied as the thermal interruption strip 302 is beingformed, before, or after the thermal interruption strip has been formed.The film 304 is applied longitudinally along the linear extent of thethermal stock 310. In one example embodiment, the film 304 is placedwithin the mold prior to injection of the thermal material. In thisembodiment, a lower layer 304 b of the film 304 (see FIG. 13) is placedin the mold and in partial contact with the first and second metal stockportions 306, 308 and an upper layer 304 a of the film is placed overthe thermal interruption strip 302 and over at least a portion of thefirst and second metal stock portions. The heat from the mold links thefilm 304 to the thermal interruption strip 302 and the first and secondmetal stock portions 306, 308. The film 304 is applied via at least oneof glue or adhesive, thermal pressure, etc, and/or a combinationthereof. In another example embodiment, the film 304 is applied priorto, during, or after the thermal stock 310 is roll formed into itschannel shape. The film 304 is airtight and prevents fluid transfersfrom inside the IGU 333 to outside the IGU. Additionally, the film 304prevents the desiccant 319 from escaping the IGU 333. In one exampleembodiment, the film 304 comprises a sputtered metal barrier, and isapplied to the thermal stock 310 before roll forming or around theperimeter of the unit 333 after roll forming but before folding theframe 316 into a rectangle. The film 304 stretches around the corners332 as the frame 316 is bent, adding strength and support to the ribbons306 and 308 with the thermal interruption strip 302. An example of asuitable film 304 is 3M's ‘Very Low Outgassing High Shear PolyesterTape’ sold as model 8439, ‘Low Outgassing Polyester Tape’ sold undermodel number 8333, ‘Very Low Outgassing Linered Polyester Tape’ sold asmodel number 6690, and ‘Aluminum Foil Tape’ sold as model number 431 or439L (Linered). The product specification sheets of these film materialsare incorporated herein by reference in their entireties and for allpurposes.

In another example embodiment, the thermal interruption strip 302 formsfirst and second projections 371 a, 372 a, illustrated in dashed linesin FIG. 14A. In this illustrated example embodiment, the first gas fillaperture 371 comprises the first projection 371 a through the base wall340 a into the channel and the second gas fill aperture 372 comprises asecond projection 372 a into the channel, wherein the first projectioninterweaves with the second projection when assembled. The interweavingprovides a friction connection. The friction connection is a responsivetactile connection, in that it provides to the assembler feedback ifthere is over-travel or under-travel when advancing one or both of theconnecting structure 334 and the opposite channel 355 towards eachother. That is, the friction during assembly remains high duringunder-travel until the interweaving of the projections 371 a, 372 asachieved to form the friction or responsive tactile connection. Once theinterweaving is achieved, the friction significantly diminishes betweenthe base wall 340 a and the second projection 372 a. Similarly, ifover-travel from the tactile connection occurs, the frictionsignificantly increases. This tactile response occurs because the secondprojection 372 a rubs the base wall 340 a of the connecting structure334, until the tactile connection is reached between the first andsecond projections 371 a, 372 a. Further discussion as to the first andsecond projections, and the tactile connection is discussed in U.S.Provisional Pat. App. No. 62/402,312 and U.S. nonprovsional patentapplication Ser. No. 15/720,892 filed Sep. 29, 2017 which areincorporated herein by reference.

Thermal Analysis

Although the patterns and/or composition of the inner edges 303 b, 307 bof the metal stock portions 306, 308 vary, an isotherm that simulatesthe thermal energy transfer of this spacer system can be generated byperforming a thermal analysis. FIG. 15A illustrates an isotherm of thetypical IGU 10 and FIG. 15B illustrates the thermal IGU 333, both IGUsbeing subjected to boundary temperature of 0° F. outside 15 a, 315 a and70° F. inside 15 b, 315 b, respectively. The lines on the isotherms arejoining points representing states of equal temperature, wherein thetemperature in Fahrenheit corresponds to the line as shown in a boxoverlaying the line.

In the illustrated example embodiment of FIG. 15B, the model illustrateswhere the frame stock portions 306, 308 are separated by the thermalinterruption strip 302, wherein the gap distance 311 is ⅛″ (inches). Itwould be understood by one of ordinary skill in the art that a greatergap distance 311 would cause a greater interruption in the thermalenergy transfer. Comparing the traditional IGU 10, which has an insidelite 15 b temperature of 34.9 F, to the thermal IGU 333, which has aninside lite 315 a temperature of 48.3 F, illustrates that less thermalenergy is lost when the thermal IGU 333 is being utilized.

In the foregoing specification, specific embodiments have beendescribed. However, one of ordinary skill in the art appreciates thatvarious modifications and changes can be made without departing from thescope of the disclosure as set forth in the claims below. Accordingly,the specification and figures are to be regarded in an illustrativerather than a restrictive sense, and all such modifications are intendedto be included within the scope of present teachings.

The benefits, advantages, solutions to problems, and any element(s) thatmay cause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeatures or elements of any or all the claims. The disclosure is definedsolely by the appended claims including any amendments made during thependency of this application and all equivalents of those claims asissued.

Moreover in this document, relational terms such as first and second,top and bottom, and the like may be used solely to distinguish oneentity or action from another entity or action without necessarilyrequiring or implying any actual such relationship or order between suchentities or actions. The terms “comprises,” “comprising,” “has”,“having,” “includes”, “including,” “contains”, “containing” or any othervariation thereof, are intended to cover a non-exclusive inclusion, suchthat a process, method, article, or apparatus that comprises, has,includes, contains a list of elements does not include only thoseelements but may include other elements not expressly listed or inherentto such process, method, article, or apparatus. An element proceeded by“comprises . . . a”, “has . . . a”, “includes . . . a”, “contains . . .a” does not, without more constraints, preclude the existence ofadditional identical elements in the process, method, article, orapparatus that comprises, has, includes, contains the element. The terms“a” and “an” are defined as one or more unless explicitly statedotherwise herein. The terms “substantially”, “essentially”,“approximately”, “about” or any other version thereof, are defined asbeing close to as understood by one of ordinary skill in the art, and inone non-limiting embodiment the term is defined to be within 10%, inanother embodiment within 5%, in another embodiment within 1% and inanother embodiment within 0.5%. The term “coupled” as used herein isdefined as connected, although not necessarily directly and notnecessarily mechanically. A device or structure that is “configured” ina certain way is configured in at least that way, but may also beconfigured in ways that are not listed.

The Abstract of the Disclosure is provided to allow the reader toquickly ascertain the nature of the technical disclosure. It issubmitted with the understanding that it will not be used to interpretor limit the scope or meaning of the claims. In addition, in theforegoing Detailed Description, it can be seen that various features aregrouped together in various embodiments for the purpose of streamliningthe disclosure. This method of disclosure is not to be interpreted asreflecting an intention that the claimed embodiments require morefeatures than are expressly recited in each claim. Rather, as thefollowing claims reflect, inventive subject matter lies in less than allfeatures of a single disclosed embodiment. Thus, the following claimsare hereby incorporated into the Detailed Description, with each claimstanding on its own as a separately claimed subject matter.

1. A spacer frame for separating first and second glass lites from eachother in an insulating glass unit (IGU) for use in fabricating a window,the spacer frame comprising: an elongated frame forming a multi-sidedform comprising a first outwardly facing surface and a second outwardlyfacing surface, the first outwardly facing surface for supporting thefirst glass lite, the first outwardly facing surface is contiguous witha first intermediate wall portion, and the second outwardly facingsurface for supporting the second glass lite, the second outwardlyfacing surface is contiguous with a second intermediate wall portion,wherein the first and second intermediate wall portions comprise a firstmaterial and are linked to each other and spaced from each other by athermal interruption strip, the first and second intermediate wallportions and the thermal interruption strip comprise an intermediatewall that bridges the first and second outwardly facing surfaces; and afilm for preventing fluid leakage, overlaying the intermediate wallportion.
 2. The spacer frame of claim 1 wherein the film is applied overthe intermediate wall portion on at least one side of the spacer frame.3. The spacer frame of claim 1 wherein: the first material comprises afirst thermal conductivity; the thermal interruption strip comprises asecond thermal conductivity, wherein said second thermal conductivity isless than the first thermal conductivity.
 4. The spacer frame of claim 1wherein the thermal interruption strip comprises a material that isflexible enough to be wound on a roll.
 5. The spacer frame of claim 1wherein the first and second intermediate wall portions comprisecomplementary intruding and protruding undulations.
 6. The spacer frameof claim 1 wherein at least a portion of the first and secondintermediate wall portions comprise interruptions.
 7. The spacer frameof claim 6 wherein said interruptions comprise at least one of holes andmesh material.
 8. Thermal stock for use in forming a spacer frame foruse in an insulating glass unit (IGU), the thermal stock comprising:first and second frame stock portions comprising a first thermalconductivity; a thermal interruption strip coupling the first framestock portion to the second frame stock portion, the thermalinterruption strip spacing the first frame stock portion a gap distancefrom the second frame stock portion, the thermal interruption stripcomprising a second thermal conductivity, said second thermalconductivity is less than the first thermal conductivity; and wherein anintermediate wall portion comprising the thermal interruption strip iscovered by a film material for preventing fluid leakage.
 9. The thermalstock of claim 8, wherein the thermal interruption strip comprises acentral portion, an upper portion, and a lower portion, said centralportion spaces the first and second frame stock portions from eachother, said upper portion extend over at least an upper portion of thefirst and second frame stock portions, and said lower portion extendover at least a lower portion of the first and second frame stockportions.
 10. The thermal stock of claim 9, wherein the film is appliedover at least one of the upper and lower portions of the thermalinterruption strip.
 11. The thermal stock of claim 10, wherein the filmis in direct contact with at least a portion of the first and secondframe stock portion.
 12. A method of forming thermal stock for use ininsulating glass units, the method comprising: forming a first andsecond frame stock portion; laterally linking the first and second framestock portions via a thermal interruption strip, the thermalinterruption strip spacing the first frame stock portion from the secondframe stock portion, and the thermal interruption strip comprising alower thermal conductivity material than the first and second framestock portions; and overlaying the thermal interruption strip and atleast a portion of the first and second frame stock portions with afilm.
 13. The method of claim 12 wherein the step of laterally linkingcomprises adhesively bonding the first and second frame stock portionsto the thermal interruption strip.
 14. The method of claim 13 whereinthe first and second frame stock portions are elongated, generallyplanar strips of a first material and wherein the thermal interruptionstrip includes separate layers having said lower thermal conductivitythat are adhesively bonded to a first and second exposed surfaces of thegenerally planar strips.
 15. The method of claim 14 wherein the thermalinterruption strip comprises three layers wherein a middle layer isadhesively attached to two additional layers that are adhesively bondedto the exposed surfaces of the generally planar strips.
 16. The methodof claim 15 wherein the step of laterally linking comprises extrudingthe thermal interruption strip into contact with the first and secondframe stock portions.
 17. The method of claim 16 where the thermalinterruption strip is extruded at an elevated temperature which hardensafter coming in contact with the first and second frame stock portions.18. The method of claim 12 wherein the step of laterally linkingcomprises molding the thermal interruption strip into contact with thefirst and second frame stock portions.
 19. The method of claim 12additionally comprising roll forming first and second frame stockportions to form a channel subsequent to linking the first and secondframe stock portions with the thermal interruption strip and wherein thefilm is applied subsequent to said bending.
 20. An insulating glass unitcomprising: first and second glass lites spaced apart from each otherhaving inner facing surfaces that bound an interior region; amulti-sided channel shaped composite spacer frame for arranging saidfirst and second glass lites in a spaced apart, generally parallelrelation to each other, said spacer frame comprising: an elongatedthermal interruption strip forming a middle portion of said compositespacer frame that extends around a periphery of the interior regionbound by the first and second glass lites; a first elongated metal sidewall member having a first outwardly facing side wall surface fororienting the first glass lite and a first inwardly facing side wallsurface that bounds the interior region wherein the first elongatedmetal side wall member includes a first embedded portion securing thefirst metal side wall member to the thermal interruption strip; and asecond elongated metal side wall member having a second outwardly facingside wall surface for orienting the second glass lite and a secondinwardly facing side wall surface that bounds the interior regionwherein the second elongated metal side wall member includes a secondembedded portion securing the second metal side wall member to thethermal interruption strip; an adhesive material interposed between theoutwardly facing side wall surfaces of said first and second metal sidewall members and the first and second glass lites for arranging thefirst and second glass lites in spaced relation to each other; and avapor barrier overlying at least a portion of the thermal interruptionstrip to impede contaminants from reaching the interior region boundedby the first and second glass lites.
 21. (canceled)
 22. (canceled)